Confidential Client
Western USA
Power & Energy
Overview
Reliable electrical power systems are fundamental to the operation of modern society, supporting industries, businesses, healthcare systems, transportation networks, and critical infrastructure across the United States. Maintaining the stability and resiliency of the US power grid requires generating facilities to have dependable startup capabilities, especially during widespread grid disturbances or power outages. Traditional generating stations typically rely on the electrical grid to provide the power necessary to restart plant systems following an outage. However, when the grid itself is unavailable, an alternate source of startup power is required, a process known as a black start.
To improve resiliency and modernize black start capabilities, the facility owner pursued the implementation of a Battery Energy Storage System (BESS) to support black start operations for a large combined-cycle generating facility. The project centered on the development of a 12 MWh battery energy storage system capable of providing startup power to a generating station with a total generation capacity of approximately 619 MW. In addition to enhancing reliability, the project introduced a cleaner and more sustainable approach to black start operations by leveraging battery-based energy storage rather than traditional solutions.
Nexus Engineering Group was engaged directly by the facility owner to provide engineering consulting, technical analysis, system integration support, and project execution guidance. The primary objective was to evaluate, define, and support the successful implementation of a BESS-based black start solution that would integrate safely and effectively with existing plant infrastructure while supporting the operational requirements of the facility.
Challenge
Implementing a battery energy storage system for black start service presented several complex technical challenges that required specialized power system expertise and a deep understanding of plant operations. Unlike conventional energy storage applications, the BESS was required to perform a highly specialized function within a dynamic and demanding operating environment.
A key challenge involved supplying sufficient power to start multiple large induction motors that provide critical auxiliary services necessary for bringing the generating units online. These auxiliary loads are substantial and must be energized in a carefully sequenced manner to support the startup of the facility's primary generation equipment. The battery energy storage system needed to maintain stable voltage and frequency while supporting these significant transient loads during startup conditions.
The project also required the BESS to support multiple black start attempts if initial startup efforts were unsuccessful. This demanded careful evaluation of battery capacity, load profiles, operating margins, and system performance requirements to ensure reliable operation under a range of potential scenarios. The system needed to reserve sufficient capacity to support its own operating loads while simultaneously providing the energy necessary to power plant auxiliaries throughout the startup sequence.
Another significant technical challenge involved the transition between operating modes. The battery energy storage system was required to establish and maintain grid-forming capability during black start operations, synchronize with newly started turbine generators, and seamlessly transfer from grid-forming to grid-following mode once generation was established. Accomplishing this transition required careful coordination between the BESS, generation equipment, and existing plant electrical infrastructure to ensure system stability and reliability throughout the process.
Solution
Nexus addressed these challenges by providing comprehensive engineering and technical consulting services throughout project development and implementation. Leveraging extensive experience in both black start strategies and battery energy storage system applications, Nexus worked closely with the owner to establish project requirements, define scope, and support procurement and implementation activities.
The team began by evaluating the existing plant auxiliary electrical systems and analyzing how a battery energy storage system would interact with facility operations during both normal and emergency conditions. Detailed system studies and engineering assessments were performed to validate the technical feasibility of the proposed solution and identify key design requirements needed to support reliable black start operation.
Nexus also supported development of project specifications and contract parameters for the BESS provider, ensuring that system performance requirements aligned with the facility's operational objectives and startup needs. Engineering support included electrical system analysis, development of single-line diagrams, review of construction documentation, and evaluation of technical studies prepared throughout project execution.
A critical element of the project was the development and review of a high-voltage generator synchronization strategy capable of supporting the transition from battery-supported operation to generator-supported operation. Nexus provided technical guidance throughout engineering, procurement, construction, and startup activities to help ensure successful system integration and long-term operational reliability.
Through a combination of power system expertise, battery energy storage system experience, and intimate knowledge of generating facility operations, Nexus helped deliver an innovative black start solution that enhances grid resiliency, supports reliable facility startup capabilities, and demonstrates the growing role of battery energy storage systems in modern electrical power systems.
Services Provided
- Conceptual engineering and design support
- Battery energy storage system (BESS) integration consulting
- Power system analysis and studies
- Electrical system evaluations
- Single-line diagram development
- Review of engineering, procurement, and construction deliverables
- Load profile evaluation and performance analysis
- High-voltage generator synchronization support
- Procurement support
- Construction support
- Startup and commissioning assistance
- As-built documentation and project closeout support
Project Director
Dennis Hill - Project Director
About Nexus Engineering Group
Nexus Engineering Group is a full-service, independent engineering, procurement, and construction management (EPCm) firm headquartered in Cleveland, Ohio, with offices in Toledo, Ohio; Columbus, Ohio; Midland, Michigan; and Oak Brook, Illinois. Founded in 2005, Nexus partners closely with clients to support project goals from concept through startup, delivering practical, reliable solutions across the refining, petroleum midstream, chemical, manufacturing, power & energy, and renewables markets.
Nexus integrates engineering, procurement, and construction management services to help clients plan and execute complex projects with confidence. Through close collaboration and a client-first approach, Nexus supports informed decision-making, manages project risk, and delivers practical solutions that enhance safety, reliability, and long-term project value.
